Process to produce polymers

ABSTRACT

A process to produce ethylene polymers is provided.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a divisional of co-pending U.S. Patent Application Ser. No. 09/222,659 filed Dec. 30, 1998, which is incorporated herein in its entirety by reference.

FIELD OF THE INVENTION

[0002] This invention is related to the field of processes that produce polymers, where said polymers comprise polymerized ethylene. The phrase “ethylene polymers” as used in this application includes homopolymers of ethylene, and copolymers of ethylene with another monomer.

BACKGROUND OF THE INVENTION

[0003] There are many production processes that produce ethylene polymers. Ethylene polymers are utilized in many products, such as, for example, films, coatings, fibers, and pipe. Producers of such ethylene polymers are continuously conducting research to find improved ethylene polymers.

[0004] This invention provides ethylene polymers with improved properties.

SUMMARY OF THE INVENTION

[0005] It is an object of this invention to provide a process to produce a catalyst system.

[0006] It is another object of this invention to provide said catalyst system.

[0007] It is another object of this invention to provide a process to use said catalyst system to polymerize ethylene, or to copolymerize ethylene with at least one other monomer, to produce ethylene polymers.

[0008] It is another object of this invention to provide said ethylene polymers.

[0009] It is yet another object of this invention to provide a process to use said ethylene polymers to produce a manufacture.

[0010] It is still another object of this invention to provide a manufacture comprising said ethylene polymers.

[0011] In accordance with this invention a process is provided. This process comprises blending a first component and a second component to produce a catalyst system wherein:

[0012] (1) said first component of said catalyst system comprises chromium on a support, and wherein the amount of said chromium on said support is from about 0.05 to 5 weight percent based on the weight of said support, and wherein said support comprises fluorided alumina, and wherein said support has a surface area from about 200 to about 550 square meters per gram, and wherein said support has a pore volume from about 0.7 to about 2.5 cubic centimeters per gram, and wherein said first component has been activated at a temperature in the range of about 500° C. to about 900° C.; and

[0013] (2) said second component is a transition metal halide catalyst.

[0014] In another embodiment of this invention, a composition comprising said catalyst system is provided.

[0015] In another embodiment of this invention, a process is provided comprising: polymerizing ethylene, or copolymerizing ethylene with at least one other monomer, to produce ethylene polymers, wherein said polymerizing is conducted in a polymerization zone, and wherein said polymerizing is conducted using said catalyst system, and wherein said polymerizing is conducted in the presence of a first cocatalyst and a second cocatalyst, and wherein said first cocatalyst comprises trialkyl boron, and wherein said second cocatalyst comprises trialkyl aluminum.

[0016] In yet another embodiment of this invention, said ethylene polymers are provided.

[0017] In yet another embodiment of this invention, a process for using said ethylene polymers to produce a manufacture is provided.

[0018] In still another embodiment of this invention, a manufacture is provided comprising said ethylene polymers.

[0019] These and other objects of this invention will become more evident from the following description and claims.

DETAILED DESCRIPTION OF THE INVENTION

[0020] A process comprising blending a first component and a second component to produce a catalyst system, is provided.

[0021] Said blending can be accomplished by any means known to those skilled in the art. Said first component and said second component can be premixed prior to being utilized in a polymerization zone or said first and second component can be routed into a polymerization zone individually in specified portions. For example, said first and second components can be dry blended together in a mixer or added to a feed stream that leads to a reactor.

[0022] Said first component of said catalyst system comprises chromium on a support. The amount of said chromium on said support is from about 0.05 to about 5 weight percent, preferably about 0.1 to about 3 weight percent, and most preferably from 0.8 to 2.5 weight percent, where such weight percents are based on the weight of the support. The chromium is usually in the form of chromium oxide.

[0023] The support comprises fluorided alumina.

[0024] The phrase “fluorided alumina” is meant to describe an alumina treated with a fluorine-containing compound, in order to add fluoride to said alumina. Reaction of the fluorine-containing compound with an alumina can take place on impregnation or on activation. Generally, the fluoride is added to said alumina by forming a slurry of the alumina in a solution of the fluoriding agent and a suitable solvent such as alcohol or water. Particularly suitable are one to three carbon atom alcohols because of their volatility and low surface tension. A suitable amount of the solution is utilized to provide the desired concentration of fluoride on the alumina after drying. Drying can be effected by any method known in the art. For example, said drying can be completed by suction filtration followed by evaporation or drying under vacuum. The alumina can also be calcined prior to being treated with fluoride and/or chromium, such as in air at about 200 to about 800° C.

[0025] Any organic or inorganic fluorine-containing compound which can form a fluoride with alumina can be used in this invention. Suitable fluorine-containing compounds include, but are not limited to, hydrofluoric acid (HF), ammonium fluoride (NH₄F), ammonium bifluoride (NH₄HF₂), ammonium fluoroborate (NH₄BF₄), ammonium silicofluoride ((NH₄)₂SiF₆), and mixtures thereof. The most preferred fluorine-containing compound is ammonium bifluoride, due to ease of use and availability. The amount of fluoride on said support is generally in the range of about 1 to about 10, preferably about 3 to about 8 weight percent fluoride, based on the weight of the support.

[0026] The support should have a surface area from about 200 to about 550 square meters per gram. It is more preferred when the support has a surface area from about 225 to about 425 square meters per gram, and it is most preferred when said support has a surface area from 250 to 400 square meters per gram.

[0027] The fluorided support should have a pore volume from about 0.7 to about 2.5 cubic centimeters per gram. It is more preferred when the support has a pore volume from about 0.8 to about 1.8 cm³/g, and it is most preferable when said support has a pore volume from 1 to 1.7 cm^(3/) gram.

[0028] Methods of producing said first component are known in the art. See, for example, U.S. Pat. Nos. 3,900,457; 4,081,407; 4,392,990; 4,405,501; 4,735,931; 4,981,831; the disclosures of which are hereby incorporated by reference.

[0029] Said first component should be activated in an oxidizing ambient at a temperature from about 500 to about 900° C. It is even more preferred when the temperature is from about 550 to about 700° C., and it is most preferred when the temperature is from 550 to 650° C. Currently, the preferred oxidizing ambient is air. This activation is carried out for a time period of about 1 minute to about 50 hours. This allows for at least a portion of any chromium in a lower valance state to be converted to a hexavalent state.

[0030] Said first component after being activated is preferably reduced. This reduction converts at least a portion of the hexavalent chromium to a lower valent state. Carbon monoxide is preferably used in this reduction. In general, this reduction is conducted at a temperature in the range of about 200 to 500° C., preferably 300-400° C., for about 1 minute to about 24 hours. After this reduction the first component is flushed with nitrogen to remove the reducing agent.

[0031] Said second component comprises a transition metal halide catalyst as disclosed in U.S. Pat. No. 4,325,837, herein incorporated by reference. Generally, said transition metal halide catalyst comprises a metal halide compound and a transition metal compound. Said metal halide compound is selected from the group consisting of metal dihalides and metal hydroxyhalides. Currently, titanium is the preferred transition metal and magnesium dichloride is the preferred metal halide.

[0032] Optionally, said second component can further comprise an anti-caking agent. Generally, said anti-caking agent comprises a fumed refractory oxide. Said fumed refractory oxide can be selected from the group consisting of fumed silica, fumed titanium dioxide, and fumed alumina. Fumed refractory oxide is disclosed in U.S. Pat. No. 5,179,178, herein incorporated by reference. Said anti-caking agent can be added to said second component in an amount ranging from about 2 weight % to about 20 weight % based on the weight of the second component.

[0033] In another embodiment of this invention, a process is provided comprising polymerizing ethylene, or copolymerizing ethylene and at least one other monomer, to produce an ethylene polymer.

[0034] Said “at least one other monomer” can be olefins having from 4 to about 16 carbon atoms per molecule. Suitable monomers, that can be polymerized with ethylene to produce copolymers with excellent properties, include, but are not limited to, 1-butene, 1-pentene, 4-methyl-1-pentene, 1-hexene, 1-octene.

[0035] This polymerizing is conducted in a polymerization zone. Polymerization can be carried out in any manner known in the art such as gas phase, solution or slurry polymerization conditions. Said polymerization zone includes any reactor known in the art. For example, a stirred reactor can be utilized for a batch process, or the polymerizing can be carried out continuously in a loop reactor.

[0036] A preferred polymerization technique is that which is referred to as a particle form, or slurry process, wherein the temperature is kept below the temperature at which the polymer becomes soluble in the diluent. Such polymerization techniques are well known in the art and are disclosed, for instance, in Norwood, U.S. Pat. No. 3,248,179, the disclosure of which is hereby incorporated by reference.

[0037] Two preferred polymerization methods for the slurry process are those employing a loop reactor of the type disclosed in Norwood and those utilizing a plurality of stirred reactors either in series, parallel or combinations thereof wherein the reaction conditions are different in the different reactors.

[0038] Said polymerizing is conducted at a temperature from about 80 to about 110° C. However, it is preferred when said polymerizing is conducted at a temperature from about 85 to about 95° C.

[0039] Said polymerizing is conducted in the presence of a first cocatalyst and a second cocatalyst. Said first cocatalyst comprises trialkyl boron. In general, the alkyl groups of the trialkylboron cocatalyst should have from about 1 to about 10 carbon atoms and preferably 2 to 4 carbon atoms. Examples include, but are not limited to, triethylboron, tripropylboron, and trimethylboron. However, most preferred is triethylboron. The amount of trialkylboron used in a polymerization, stated in parts per million by weight, based on the weight of the diluent in the reactor, is from about 0.01 parts per million to about 20 parts per million. Preferably, it is from about 0.05 parts per million to about 10 parts per million, and most preferably it is from 0.5 parts per million to 8 parts per million.

[0040] Said second cocatalyst comprises trialkylaluminum. Generally, the alkyl groups of the trialkylaluminum cocatalyst should have from about 1 to about 10 carbon atoms and preferably, 2 to 4 carbon atoms. Examples, include, but are not limited to, triethylaluminum, tripropylaluminum, and trimethylaluminum. However, most preferred is triethylaluminum. The amount of trialkylaluminum used in the polymerization, in parts per million by weight, based on the weight of the diluent in the reactor, is from about 0.01 parts per million to about 20 parts per million, preferably, it is from about 0.05 parts per million to about 10 parts per million. Most preferably, it is from 0.5 to 8 parts per million.

[0041] Hydrogen is present in the polymerization zone. Currently, about 0.5 to about 3 mole percent hydrogen is used. However, it is preferred when about 0.8 to about 2.5 mole percent is present in said polymerization zone, and it is more preferred when 1.2 to 2.2 mole percent of hydrogen is present in said polymerization zone. These mole percents are based on the moles of the diluent in said polymerization zone.

[0042] Said ethylene polymers can be used to produce manufactures. Said ethylene polymers can be formed into a manufacture by any means known in the art. For example, said ethylene polymers can be formed into a manufacture by blow molding, injection molding, and extrusion molding. Further information on processing said ethylene polymers into a manufacture can be found in MODERN PLASTICS ENCYCLOPEDIA, 1992, pages 222-298.

[0043] One important application for said ethylene polymers is the production of pipe. Pipe produced from said ethylene polymers typically are formed from an extrusion process. Further information on manufacturing pipe can be found in PLASTICS MATERIALS AND PROCESSES, 1982, pp. 591-592.

[0044] It is preferred when said ethylene polymers have a HLMI of about 2-20, preferably about 5-15, and most preferably 8-13 grams per ten minutes.

[0045] It is also preferred when said ethylene polymers have a density of about 0.945-0.955, preferably about 0.947-0.953, and most preferably 0.948-0.951 grams per cubic centimeter.

[0046] It is also preferred when said ethylene polymers have a shear ratio (HLMI/MI) of greater than about 300, preferably greater than 400, and most preferably greater than 500.

[0047] It is also preferred when said ethylene polymers have a polydispersity (Mw/Mn) of greater than about 40, preferably greater than 50, and most preferably greater than 60.

[0048] It is also preferred when the ethylene polymers have a pent test of greater than about 500, preferably greater than 1000, and most preferably greater than 2000.

EXAMPLES

[0049] These examples are provided to further illustrate the invention.

[0050] The following analytical methods were utilized.

[0051] The density was determined in grams per cubic centimeter (g/cc) on a compression molded sample, cooled at 15° C. per hour, and conditioned for 40 hours at room temperature in accordance with ASTM D1505 and ASTM D1928, procedure C.

[0052] The high load melt index (HLMI, g/10 min) was determined in accordance with ASTM D1238 at 190° C. with a 21,600 gram weight.

[0053] The melt index (MI, g/10 min) was determined in accordance with ASTM D1238 at 190° C. with a 2,160 gram weight.

[0054] The Pent test was determined in accordance with ASTM F 1473-94.

[0055] The Tensile Strength was determined in accordance with ASTM D 638.

[0056] The polydispersity (Mw/Mn) was determined using size exclusion chromatography analyses that were performed at 140° C. on a Walters, model 150 GPC with a refractive index detector. A solution concentration of 0.25 weight percent in 1,2,4 trichlorobenzene was found to give reasonable elution times.

[0057] The polymers in these examples were prepared in a continuous, particle form process by contacting a catalyst system with ethylene and 1-hexene. A liquid full 15.2 cm diameter pipe loop reactor having a volume of 87 liters was utilized. Isobutane was used as the diluent. Hydrogen was employed. The reactor was operated to have a residence time of 1.25 hours.

[0058] The first component of the catalyst system was added through a 0.35 cc circulating ball-check feeder, and the second component of the catalyst system was added simultaneously to the reactor through a separate 0.08 cc ball check feeder. The reactor temperature was set at 88° C., depending on the particular experiment, and the pressure was 4.1 Mpa (590 psig). The ethylene polymer was removed from the reactor and recovered in a flash tank. A vulcan dryer was used to dry the ethylene polymer under nitrogen at about 60 to 80° C.

[0059] The following feedstocks were utilized in the experiments. Ethylene that had been dried over alumina was used as a monomer. Isobutane that had been degassed by fractionation and dried over alumina was used as the diluent. Triethylboron or triethylaluminum was also sometimes used as cocatalysts as indicated in the examples below.

[0060] A first component was made from a commercially available alumina obtained from AKZO Nobel as Ketjen Grade L alumina, which contained 2% silica. This alumina had a pore volume by water adsorption of 2.1 cc/gm and a surface area of about 350 square meters per gram after calcining at 600° C. Chromium was added to this alumina, along with a fluorine-containing compound, to form the first component of said catalyst system. This was accomplished by impregnating the support to incipient wetness or somewhat less, with a methanol solution of chromium (III) nitrate containing 0.5 g Cr/100 ml. This chromium containing support was then dried under vacuum for 8 hours at 110° C. Then, the chromium containing support was treated with a methanol solution of ammonium bifluoride before being dried again under vacuum at 110° C. to produce said first component. Said first component of said catalyst system contained 2 wt % Cr and 6 wt % ammonium bifluoride based on the weight of the support. To activate said first component, it was calcined at about 590° C. in dry air in a fluidized bed for 6 hours, then it was cooled in nitrogen to 370° C. and exposed to carbon monoxide for two hours, followed by flushing with pure nitrogen for 30 minutes and then cooled down to room temperature and stored under nitrogen.

[0061] A second component of said catalyst system was prepared according to U.S. Pat. No. 4,325,837. Said second component was prepared by contacting magnesium dichloride and titanium ethoxide in xylene to obtain a solution, then contacting the solution with ethyl aluminum dichloride to obtain a solid, then contacting the solid with ethylene to obtain a prepolymerized solid, and then contacting the resulting prepolymerized solid with titanium tetrachloride to form said second component. Said second component contained about 10 wt % titanium and about 10 wt % prepolymer. Said second component was then treated with a heptane solution of triethyl aluminum (TEA) containing enough TEA to equal 0.6 mole of aluminum for each mole of titanium in the catalyst. A fumed silica sold by Cabot Corporation under the name HS-5 was added to said second component. The fumed silica was added as an anti-caking agent as described in U.S. Pat. No. 5,179,178 in the amount of 15 wt % based on the weight of the second component of said catalyst system.

EXAMPLE ONE

[0062] To make high quality ethylene polymer that can be used to manufacture pipe, said first component and said second component described above were introduced into the reactor simultaneously at a temperature of 88° C. The first component was fed at the rate of 80 discharges per hour and the second component at the rate of 6 discharges per hour. When corrected for activity differences between the first and second components, this corresponds to a ethylene polymer contribution of approximately 65% from said first component and 35% from said second component. Isobutane was fed to the reactor at a rate of 63.23 lbs per hour, and ethylene was fed at 28.8 lbs per hour to maintain a reactor concentration of 10.06 mole percent based on the diluent. Hydrogen concentration was held at 1.923 mol percent. 1-hexene was fed to the reactor at 3.24 lbs per hour in order to hold a concentration in the diluent of 2.677 mole percent. The cocatalyst consisted of a mixture of triethyl boron and triethyl aluminum, and it was pumped into the reactor at a rate equal to 1.30 and 5.34 ppm based on the weight of the diluent. The reactor residence time was 1.14 hours. The slurry consisted of 74.5 percent liquid diluent and 25.5 percent solid polymer. Total reactor pressure was 590 psig.

[0063] The ethylene polymer produced was analyzed, and the results are summarized in Table 1. The ethylene polymer produced was compared to TR-480, a standard high quality pipe resin sold commercially by Driscopipe Company.

[0064] Note that the invention resin has a higher tensile strength than TR-480 due to the higher density of the resin. However, this improvement was achieved without serious deterioration of the other pipe properties, as would be normally expected. This is an advantage of the invention resin.

[0065] The analytical data in Table I was also compared to a TR-480 high density resin. The density of TR-480 was raised to show the effect on pipe properties.

[0066] These results indicate that the ethylene polymer produced from the process of this invention has superior properties to the TR-480 and to the TR-480 high density control.

EXAMPLE TWO

[0067] For comparison, the first component and the second component of said catalyst system were utilized alone under the same reactor conditions described above. The ethylene polymers produced were analyzed, and the data obtained are shown in Table 2. TABLE 1 Invention TR-480 High Density Resin (Dual Catalysts) Control TR-480 Control HLMI (g/10 min) 11.5 12 7 HLMI/MI 550 110 128 Density (g/cc) .949 .944 .949 Tensile Strength, psi 3500 3250 3450 Pent Test, hrs >2000 100 53

[0068] TABLE 2 Catalyst First Component Second Component Melt Index (g/10 min) 0 50.2 High Load Melt Index 2.2 180 (g/10 min) Density (g/cc) 0.945 0.965 

That which is claimed is:
 1. A process comprising blending a first component and a second component to produce a catalyst system wherein: (1) said first component of said catalyst system comprises chromium on a support, and wherein the amount of said chromium on said support is from about 0.05 to 5 weight percent based on the weight of said support, and wherein said support comprises fluorided alumina, and wherein said support has a surface area from about 200 to about 550 square meters per gram, and wherein said support has a pore volume from about 0.7 to about 2.5 cubic centimeters per gram, and wherein said first component has been activated at a temperature in the range of about 500° C. to about 900° C.; and (2) said second component is a transition metal halide catalyst.
 2. A catalyst system produced by the process of claim
 1. 3. A catalyst system comprising a first component and a second component to produce a catalyst system wherein: (1) said first component of said catalyst system comprises chromium on a support, and wherein the amount of said chromium on said weight of said support is from about 0.05 to 5 weight percent based on the weight of said support, and wherein said support comprises fluorided alumina, and wherein said support has a surface area from about 200 to about 500 square meters per gram, and wherein said support has a pore volume from about 0.7 to about 2.5 cubic centimeters per gram, and wherein said first component has been activated at a temperature in the range of about 500° C. to about 900C; and (2) said second component is a transition metal halide catalyst.
 4. A process comprising polymerizing ethylene, or copolymerizing ethylene with at least one other monomer, to produce ethylene polymers, wherein said polymerizing is conducted in a polymerization zone, and wherein said polymerizing is conducted using said catalyst system of claim 3, and wherein said polymerizing is conducted in the presence of a first cocatalyst and a second cocatalyst, and wherein said first cocatalyst comprises trialkyl boron, and wherein said second cocatalyst comprises trialkyl aluminum.
 5. Ethylene polymers produced by the process in claim
 4. 6. Ethylene polymers having the following properties: a HLMI of 8-13 grams per ten minutes; a density of 0.948-0.951 grams per cubic centimeter, a shear ratio (HLMI/MI) of greater than 500, a polydispersity (Mw/Mn) of greater than 60, pent test of greater than
 2000. 7. A process of using said ethylene polymer in claim 6 to produce a manufacture.
 8. A manufacture produced by the process in claim
 7. 9. A manufacture according to claim 7 wherein said manufacture is pipe. 